2015/05 - Bullk Handling Today

BULK

HANDLING Endorsed by: CMA l LEEASA l SAIMechE l SAIMH l

T O D A Y May 2015

NEW CHUTE DESIGN COURSE CHANGING LOGISTICS LANDSCAPE 1

BULK HANDLING TODAY

February 2012

BULK HANDLING TODAY

May 2015

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Dump your

Let it

Megaroller has over 30 years of experience in the conveyor industry. Our Rollers are designed to last longer; therefore reducing cost of ownership. They are more belt friendly; thus limiting the risk of secondary belt damage. Globally they have become renowned for their energy efficiency, reliability and quieter operation giving our customers better results from their conveyor systems. User Friendly, Energy Efficient and Longer Lasting is why more and more customers choose our products to keep their goods rolling for longer for less. Contact us to experience the difference and see why our products keep yours rolling.

Our leading products

Innovations & Applications Standard Megahybrid Rollers are made from mild steel conveyor tubing for maximum strength. Megaroller’s patented Sealing Arrangement allows these rollers to be used in extreme temperatures and harsh weather conditions.

Anti-Run-Back Our Anti- Run-Back Technology can be applied to incline belts to prevent the belt from running back in the event of a “belt-snap”. Rollers are fitted with Megaroller’s patented Sealing Arrangement as well as a roller brake system which ensures that the roller can only run in one direction.

Anti-Static Our innovative Anti-Static Technology, comprising of a copper strip inside the roller that connects the outer shell to the shaft, can be applied to the Megaroller Hybrid Rollers. Static electricity is earthed inside the roller to mitigate the risk of an open spark in methane-rich underground mines, which presents a major fire hazard in cole and gold mines.

HDPE Rollers

Hybrid Rollers

Impact Rollers

Steering Frames

Megaroller HDPE Rollers are an innovation in reinforced high-density polyethylene (HDPE) conveyor rollers.

Megaroller Hybrid Rollers are unique combination steel / high-density polyethylene (HDPE) conveyor rollers.

Megaroller’s Impact and Rubber Disc Return Rollers absorb the impact of large loads of ore falling onto conveyor belts to prevent damage.

Megaroller’s unique Multisteer conveyor belt steering frames are the key to effective conveyor belt management.

CONTACT US: www.megarollerindustries.com | info@megaroller.co.za | +27(0)12 250 2365

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Anti-Seize The roller utilizes Megaroller’s innovative AntiSeize Technology, comprising a side flinger which remains static while the roller is running. This protects the sealing arrangement against any spillage that could get lodged between the shaft and the roller’s side face. It is specifically suggested for dusty environments, like cement factories and crusher plants.

World leader in conveyor idlers

BULK

HANDLING

T O D A Y

May 2015

Contents On The cover:

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SAIMH News

Melco Tel: (011) 255 1600 www.melcoconveyors.com

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CMA News

Endorsing Bodies

Conveying 6 9

Gaining Ground in Africa Everybody Wins

8 Leeasa

News

Growth Path

13 More Maintenance Management

Logistics

17 Embracing Change

Beltcon

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CMA (Conveyor Manufacturers Association)

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LEEASA (Lifting Equipment Engineering Association of South Africa)

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SAIMechE (SA Institute of Mechanical Engineering)

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SAIMH (SA Institute of Materials Handling)

•

also mailed to members of the RFA (Road Freight Association)

27 Measurements on Overland Conveyors 39

Market Forum

Copyright

All rights reserved. No editorial matter published in “Bulk Handling Today” may be reproduced in any form or language without written permission of the publishers. While every effort is made to ensure accurate reproduction, the editor, authors, publishers and their employees or agents shall not be responsible or in any way liable for any errors, omissions or inaccuracies in the publication, whether arising from negligence or otherwise or for any consequences arising therefrom. The inclusion or exclusion of any product does not mean that the publisher or editorial board advocates or rejects its use either generally or in any particular field or fields.

Our e-mail address is bulkhandling@promech.co.za Visit our website on www.promech.co.za

The monthly circulation is 3 673

Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401, Fax: (011) 781-1403 E-mail: bulkhandling@promech.co.za www.promech.co.za Managing Editor: Susan Custers Advertising Sales: Linda Erasmus DTP: Lindy Fobian / Jacqueline Nene Subscriptions: Please email us at accounts@promech.co.za if you wish to subscribe to “Bulk Handling Today” at R475,00 (excl postage and VAT) per year; R1 190,00 per year for Africa/Overseas.

Printed by: Typo Colour Printing, Tel: (011) 402-3468 FSC (Forestry Stewardship Accreditation)

BULK HANDLING TODAY

May 2015

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The South African Institute of Materials Handling

Sample

The South African Institute of Materials Handling (SAIMH) is a Non-Profit organisation set up with an objective to encourage the transfer of knowledge associated within the fields of Bulk Materials Handling (conveyors, stacker, reclaimers, tipplers, train loading systems, etc.) through a combination of seminars and networking sessions.

The SAIMH is made up of professional engineers, each practising their trade in a variety of organisations who volunteer their time to execute the SAIMH’s objective. The main aim is thus to promote the advancement of the art, science, theory and practice of the Bulk Materials Handling principles and techniques.

Company Affliates as at May 2015 Afripp Projects cc Brelko Conveyor Products (Pty) Ltd Bulkcon CPM Engineering CT Systems cc Conveyor Watch (Pty) Ltd David Brown Gear lndustries (Pty) Ltd ELB Engineering Services (Pty) Ltd Engicon Systems (Pty) Ltd Facet Engineering cc Flexco (SA) (Pty) Ltd

Hagglunds Drives SA (Pty) Ltd Hansen Transmissions SA (Pty) Ltd Hatch Goba (Pty) Ltd lllustech J & A Engineering Services Kimrae Engineering Prolects Loadtech Load Cells (Pty) Ltd MacsteelVRN Martin Engineering Melco Conveyor Equipment Morris Material Handling SA (Pty) Ltd

Osborn Engineered Products (Pty)Ltd PD Engineering Services cc PH Projects Holdings (Pty) Ltd Rio Carb (Pty) Ltd Sandvik Materials Handling Africa Screw Conveyors & Material Handling Senet SEW Eurodrive Spar Western Cape SSAB South Africa (Pty) Ltd Tenova Zest Electric Motors (Pty) Ltd

4 BULK TODAY 2015 Tel: (011)HANDLING 867-0902 l Fax:May (011) 867-0036 l Email: saimh@global.co.za l www.saimh.co.za

CONVEYOR MANUFACTURERS ASSOCIATION

From The Chairman’s Desk The 42nd Annual Dinner was held at Bryanston Country Club in May and was a most enjoyable evening. Members and guests were treated to a very interesting and informative talk by local wine expert, Linda Sandilands, on the wines that were served that evening and Havana Gas provided the music. Bryanston Country Club served a tasty buffet with carvery which was a move away from the more formal plated meal.

Simon Curry

Alan Exton

Two Awards of Excellence were made this year. We recognised the ‘outstanding contribution in assisting the promotion of excellence in belt conveying technology’ made by Brian Townsend in his role as Financial Manager to the CMA over the past 20-plus years.

tion of excellence in belt conveying technology’.

Alan received his first Award of Excellence way back in 2008 and is unfailing in his hard work and dedication to all CMA activities.

The second award was made to Alan Exton for his ‘continued and outstanding contribution to the promo-

Simon Curry Chairman

Brian Townsend

Membership at May 2015 All members subscribe to the CMA Code of Ethics ABB Industry Actom Afripp Projects Atlanta Manufacturing Bauer Bearings International Belt Brokers Belt Reco Belting Supply Services Bibby Turboflex BMG Bonfiglioli Power Transmissions Bosworth Brelko Conveyor Products Brevini Power Transmission SA (Pty) Ltd CedoTech cc Collisen Engineering Conveyor & Engineering Equipment Conveyor Watch CPM Engineering CT Systems David Brown Gear Industries DRA Projects SA (Pty) Ltd Dunlop Belting Products Dymot Engineering Company

ELB Engineering Services Facet Engineering Fenner Conveyor Belting (South Africa) Flexco SA (Pty) Ltd FLSmidth Roymec Hägglunds Drives South Africa Hansen Transmissions SA Hatch Goba Africa Hosch - Fördertechnik (SA) International Belting & Marketing Iptron Technology Lesa Mining Equipment and Conveyor Belt Lorbrand M & J Engineering Martin Engineering Megaroller Melco Conveyor Equipment Moret Mining MS Conveyor Pulleys SA Nepean Conveyors NSK South Africa (Pty) Ltd OE Bearings Oriental Rubber Industries SA Osborn Engineered Products Pegasus Industrial Services cc

PH Projects Holdings Protea Conveyors Read Swatman & Voigt Regal Beloit South Africa Rema Tip Top South Africa Renold Crofts Rula Bulk Materials Handling Sandvik Materials Handling SA Schaeffler South Africa SENET SEW Eurodrive Shaft Engineering Shaw Almex Africa SKF South Africa Sprag Components cc Tenova Takraf ThyssenKrupp Industrial Solutions South Africa (Pty) Ltd Timken South Africa (Pty) Ltd Transmission Components Transvaal Rubber Company TWP Projects Veyance Technologies Africa Voith Turbo Zest Electric Motors

BULK HANDLING TODAY

May 2015

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CONVEYING

Gaining Ground In Africa Leveraging off the expertise and experience of their Australian counterparts, Nepean Conveyors is fully poised to deliver complete engineered turnkey conveying solutions to the African market – and not only in the mining sector.

“Bulk Handling Today” finds out more.

The Boggabri coal terminal in Australia where Nepean completed the design and construction of a1500tph stockpiling system

L

ocally Nepean Conveyors has traditionally been associated with mining conveyor systems in the underground coal market but there is far more to the company than meets the eye.

Howard Areington, Sales Manager: Africa, says the company is easily able to supply solutions for overland applications and port facilities, as has been the case in the sectors where they are well known.

“In this regard there is scope for much work in Africa based on the projects we’ve been involved in throughout Australia and elsewhere in the world.

Nepean has the ability to deliver solutions across a broad spectrum of sectors,” he adds. One such example is the work undertaken for the Kimberley Metals Group that required a specifically designed solution.

But Africa is no easy operating environment and solutions have to be able to withstand the harsh landscape Achieving the impossible

“Our team was commissioned to design, manufacture, deliver and construct the load out jetty conveyor system for an iron ore export facility in Western Australia,” explains Howard. “Key to this project was the extremely tight delivery schedule with the shipping booked for loading for the first ore within several months of our being contracted to do the work. Previous concepts had exceeded approved budgets and significant time had already been lost.” But the impossible was achieved.

“The design of a pivot conveyor for this project was particularly challenging with the head end positioned on a floating pontoon allowing move-

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Howard Areington, Nepean Conveyors Sales Manager for Africa

ment to accommodate a 8,5m tidal range – all of which had to withstand cyclonic wind conditions.

But we met the challenge. All the deadlines were achieved and today the facility moves significant tonnages of iron ore. All the ore is loaded onto barges via a rotary stacker mounted on the pontoon. The barges transport material to waiting ships offshore for delivery to markets in Asia.”

Howard asserts that it’s precisely their ability to deliver solutions that makes the company stand out in the local market. “We have a very strong

CONVEYING

The Wyndham Barge in Australia that was designed, manufactured and constructed for the movement of iron ore is a prime example of a customised port solution

presence locally in the underground coal mining market, our traditional focus area. The opportunity going forward is to expand our local footprint across a wide range of other sectors by applying our ability to develop and deliver technologies and products to suit.”

All commodities

Howard and his team have identified several areas for bringing their underground expertise to the surface with a particular emphasis on plant conveyors across all commodities, and especially the hard rock mining environment. Gold is the one commodity in Africa that experts maintain will remain steadfast. While mining has taken a turn for the worse following the commodities crash over the last year with prices for iron ore, copper and coal reaching lower levels, the demand for gold milling and crushing remains strong.

“Anything that has to be crushed needs a conveyor which is where we come in. It’s all about remaining viable in the new business environment,” says Howard. “With traditional markets slowing down, companies have to start looking at other areas to diversify and extend their offerings.”

He believes the junior mining environment has the most potential. “This is where medium sized plants are going up and we are in a good position to service this market with conveyors and other necessary equipment.”

Infrastructure and ports

Ports are another area of interest. Infrastructure in Africa has come under the spotlight with ports playing an integral role. There is no denying the growing interest in the continent despite low commodity prices. But Africa is no easy operating environment and solutions have to be able to withstand the harsh landscape.

“Here we are ideally positioned to add value. We like the idea of big bulk handling plants as we are good at developing these particular solutions.” Nepean is able to deliver plant, overland and underground conveyors, as well as find solutions to move commodities through ports - an ability which is going to be greatly sought after, in Howard’s view.

“It’s all about adapting to market conditions,” he tells us. “Of course we will not lose sight of our traditional markets where we will endeavor to grow our services to the coal mining sector.

However, we believe it’s essential to diversify and to work across commodities by offering a range of services to clients. Africa is challenging, but companies that are able to deliver solutions that are affordable, sustainable and increase operational efficiency will be the ones that walk away with the prize.

Conveying systems can be complex so just putting in a conveyor for the sake of it does not work – even more so in Africa Leapfrog technology

“Also in Africa, it’s important to find a customized solution because one size does not necessarily fit all. Being conveyor designers and suppliers, our niche lies in that we can develop the materials handling system to suit the application.”

Howard firmly believes a conveyor is not just a conveyor. “Conveying systems can be complex so just putting in a conveyor for the sake of it does not work – even more so in Africa.” And while supplying standardised equipment has its place, the move towards tailor-made solutions is fast gaining ground.

“The operative word is that it has to be affordable,” Howard concludes. “We leverage a lot off the work undertaken by our colleagues in other areas of the world where they have developed key competencies in the mining sector which gives us an insight into what will and won’t work locally.

“We can literally leapfrog our local problems thanks to the experience and practical knowledge gained in other areas of the world. It’s a matter of transferring the information and applying it to our home ground.”

Nepean Conveyors, Howard Areington Tel: (011) 708-2854, www.nepean.com Email: howard.areington@nepean.com

BULK HANDLING TODAY

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LIFTING EQUIPMENT ENGINEERING ASSOCIATION OF SA

LEEASA, formed in 2003, is a division of the Chamber of Engineering Technology (COET), a non-profit organisation. The association’s objectives include, but are not limited to: the transfer of knowledge and training within the field of the Lifting Industry, to improve safety, promote the use of standards and to promote Professional and Ethical practices.

I

t is represented on the Engineering Council of South Africa (ECSA) and a number of ECSA committees as well as on various task teams at the South African Bureau of Standards (SABS).

What’s in it for you:

As an Individual member who is registered as a Lifting Machinery Inspector (LMI), you may qualify for any concessionary fee granted by ECSA (this could save you over R1 000 a year).

ECSA registered COET / LEEASA members are awarded one Continuing Professional Development (CPD) credit in category

3 each year. CPD is an ECSA requirement to retain registration.

Members obtain a discount on training and seminars validated by the association, especially useful in earning ECSA CPD credits.

Members benefit from the collective power of a recognised and established association and collective co-ordination in dealing with authorities in policy making and matters concerning the industry.

LEEASA has some 500 members (Individuals and Companies).

Tel/Fax: (011) 787-1302, Email: engineer@netactive.co.za, www.leeasa.mirrorz.com 8

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CONVEYING

Everybody Wins All over the world, increasing demand for bulk transport of materials has led to the significant development of conveyor systems. As these systems get larger, longer and faster, training is becoming increasingly important, not only for conveyor belts but also chute design. “Bulk Handling Today” speaks to Simon Curry, chairman of the Conveyor Manufacturers Association (CMA), about their latest training offering.

Simon Curry, chairman of the Conveyor Manufacturers Association

T

he CMA is a firm believer that the finger should be kept on the proverbial training pulse. “Not only does ongoing training address safety concerns but it ensures manufacturers are up to date with the latest developments and advances being made in the industry,” says Simon.

“Our members in particular are required to maintain a high level of technical expertise and service within their organisations with ongoing training playing a big role in attaining this goal.”

You cannot get something 40% right and expect it to work. It has to be 100%

The Association has therefore always advocated for training to remain at the top of the priority list not only for member companies but the conveyor industry at large. In this light, the CMA already offers a number of courses, with the latest chute design course being added to the list.

Solid background

Their conveyor design course offers solid training to industry. Simon adds, “The CMA offers a conveyor

certificate course to familiarise candidates with conveyors in all aspects. It’s aimed at artisans, draughtsmen, junior engineers and even sales people. Apprentices and other technical persons, who find themselves in a situation where they are employed in a capacity where conveyors are used, also benefit from this comprehensive course which covers aspects such as operating procedures, training and training belts theory, electrical and safety issues.”

Another popular course offered by the CMA is its beltsman certificate course which is aimed at familiarising attendees with the procedures applicable to looking after the belting on a conveyor system.

“A lot of effort is spent on tracking and training of the belt and prevention of spillage. It is intended for beltsmen, artisans and other operating staff where conveyors are used.”

More recently, however, questions have been raised around the need for a course on chute design. “We have been thinking for some time about adding to our training portfolio and specifically looking at a course on chute design,” Simon tells us. “It was decided that, instead of launching something new, we would rather work with an existing institution BULK HANDLING TODAY

May 2015

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ThyssenKrupp Industrial Solutions

CONVEYING

offering such a course – hence our collaboration with the University of the Witwatersrand (Wits).”

Chute design

Wits has always prided itself as an educational institution that stays in touch with industry. The University offers a wide variety of courses aimed at addressing the particular needs of industry.

Conveyors and chutes are no different and are part and parcel of the curriculum.

“Having been in discussion with Wits for some time, we have reached an agreement that will see their existing course on chute design developed slightly further to allow for more practical input and involvement from the CMA,” Simon continues.

Currently a two-day course presented by Tunra covers detailed methodologies for the calculation of bulk material trajectories, velocities and pressures that develop with material impact and flow within bulk transfer chute arrangements. Understanding internal angles of friction and how chute angles are determined and applied are included in the course. “It’s an excellent course that handles the theory very well,” Simon adds. “However, it has now been developed further with a third day covering practical training being added.”

The CMA will then set all students an assignment which students will have two months to complete and submit for marking. After submitting the assignment, students sit an examination. Achieving the pass mark for both the assignment and the examination entitles the student to a CMA Certificate in Bulk Transfer Chute Design and Modelling.

Skills development crucial

Skills remain a major concern in the conveyor industry. “The training courses are set at a very high standard because our industry requires perfection.

You cannot get something 40% right and expect it to work. It has to be 100%,” Simon asserts. Currently the conveyor design course pass mark is set at 70%. The same pass mark will be required for the chute design course.

“From a CMA perspective, it’s necessary to increase skill levels around chute design in the country. We need people in the field who understand the process

of chute design and single particle analysis in particular. Every company that does materials handling must have someone in their ranks who understands and can do single particle analysis.

It’s after all the essence of bulk handling.”

An agreement that will see their existing course on chute design developed slightly further to allow for more practical input and involvement from the CMA

He adds that the CMA is certainly not venturing out of conveyors into another arena but rather, through the course with Wits, they are helping to contribute towards improving essential skill levels around bulk conveying work. “Conveyors and chutes are intrinsically linked. Improving both sets of skills is what we require for our industry in the long run. We believe this course will do just that.

Post-graduate

“This course has traditionally proved to be a very successful post-graduate option with 40 students enrolling with Wits to study chute design last year. And this was without the added CMA element that will be included this year. We expect at least the same number of students for this year’s course and we hope to grow these numbers in the coming years.”

For Simon the CMA involvement in the chute design course is an exciting move. “Everybody wins with this course. The company wins, industry wins and the individual wins. Promoting the excellence of belt conveying dictates everything that we do at the CMA and we believe this new addition to our training initiative will add significant value.”

The course takes place in July this year. Interested parties can contact either the CMA or Wits for exact dates and costs involved.

Conveyor Manufacturers Association Simon Curry, Tel: (011) 888-7163 Email: ctr@cmasa.co.za, www.cmasa.co.za

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GROWTH PATH

More Maintenance Management The global focus on efficiency and cost of production have been key factors in the purchasing decisions of companies that are increasingly exploring ways to extend the lifespan of equipment. Maintenance has become the new buzzword. “Bulk Handling Today” speaks to Natalie Smith, sales manager at Clyde Bergemann Africa.

B

usinesses around the world have the same goal - the lowest possible cost inputs and the highest returns. All without running their assets into the ground.

Says Natalie, “Instead of buying new and replacing, there is a very real trend towards managing assets better, which is where maintenance programmes play a critical role. This is evidenced by the number of requests we have received in the past year for maintenance contracts. As a result, maintenance was identified as a growth area for us, and in 2014 we embarked on a strategy to grow this part of our business.”

With dedicated aftermarket personnel in place, as well as a sales team to market the availability of this service, several large maintenance contracts were signed during the past financial year.

Natalie Smith, sales manager, at Clyde Bergemann Africa

Now, more than ever, companies must have the ability to be agile and flexible in order to adjust strategies to fit the market environment

“As there is a worldwide trend towards renewable energy due to the environmental concerns surrounding coal-fired power stations, companies such as ours are shifting focus into other areas of the business and expanding into commercial markets,” Natalie remarks. “However, when maintained properly, and with our Air Pollution Control Systems (APCs) in place, it is possible to limit pollution from these power plants to acceptable levels.”

Changing direction

But it’s more than just about saving money through maintaining current assets rather than buying and installing new equipment. “We work extensively across the world in the power sector and are on top of the trend in the more developed countries who are investing less in traditional coal fired power stations. Therefore we are capitalising on development by expanding and growing our service offering into other areas. Being sustainable in the long run is very much under the spotlight. Like many businesses out there, well-thought out strategies to ensure future growth and expanding the company’s offering is top of mind,” Natalie tells us.

Maintenance – including departments such as servicing and spares – are the most obvious to develop. It’s all about viability and sustainability.

But maintenance too cannot be stagnant. It must evolve and add value to clients and so it’s important that new methods, processes and techniques are developed, tested and implemented as well.

“As much as maintenance is the focus, it’s not merely the ‘same old same old’. Making sure optimum methods are being implemented and new technologies introduced is as important.”

Materials handling

According to Natalie, the company has seen some major developments arise out of their decision to focus on the maintenance aspect. Working extensively in the power sector where planned outages for maintenance upgrades is a common occurrence, has also seen the company expand its client base.

A pneumatic transfer vessel in desperate need of refurbishment

“There are several lines of technology that are worth a look. We concentrate on materials handling and boiler maintenance that is further split into fulltime maintenance contracts (usually a three-year contract) and outage based contracts. Having refocused our attention on this aspect of the business, we have picked up on several leads that have led to our getting more work in other areas – be it to find solutions to a specific problem or to implement a new system.”

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► EIA Process

► Environmental Risk Assessments

► Geographical Information Systems

► Agricultural Assessment and Advise

► Project Managment

► Wetland and Riparian Services

► Natural Resource Services

► Visual Impact Assessments

► Ecological/Biodiversity Services

► Public Participation Process

► Application Assistance

► Game Ranch Management

► Developement Research, Monitoring and Evaluation

N2 Mnini ECO Duties

Plant rescue

Durban Coal Terminal Site Inspection

Ohlanga Pump station ECO Duties

Freightpak Warehouse Site Audit

Public participation Makhabeleni

Ballito Interchange Botanical survey

Site assessment Sundumbili pipeline

l Tel: (031) 303-2835 l Fax: 086 692 2547 l l Email: info@afzelia.co.za l www.afzelia.co.za l

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Skills on Site

Septmeber 2012

1

GROWTH PATH

Good as new

Growing their operations in the power sector remains a priority for the company which is focusing hard on ensuring they have the right product and service delivery at the right price for power stations - especially as this is one area that will continue to grow in Sub Saharan Africa where a shortage of power has been identified.

We have picked up on several leads that have led to our getting more work in other areas – be it to find solutions to a specific problem or to implement a new system

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Diversify

Nevertheless it’s just as important to diversify and grow in various sectors, says Natalie. “It’s a highly competitive environment out there so the ability to work across various industries is key. The plan is also to grow the business into the rest of southern Africa where there is major infrastructure development going on, especially in the power sector.

“We intend to expand across the southern part of the continent, increasing our operations in countries such as Zambia and the DRC.” Natalie maintains that now, more than ever, companies must have the ability to be agile and flexible in order to adjust strategies to fit the market environment. “In recent times, more and more projects have been put on hold as capex has been cut. Remaining sustainable means thinking out of the box and revising strategies to fit the times.”

Natalie Smith, Clyde Bergemann Africa Tel: (011) 704 0580, Email: enquiry@cbz.co.za www.cbz.co.za

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LOGISTICS

Steve Ford, CEO Barloworld Logistics

With the only certainty about the future being uncertainty, this year the annual supplychainforesight survey focused on understanding how South African companies are dealing with change under the title ‘Embracing Change for a Sustainable Future’.

Change is firmly on the radar with respondents selecting identifying and managing change as the top ranking strategic business objective for 2015. Growth and expansion into new markets ranked second, and is a continuing theme from last year’s report.

While opportunities at home have become more complex and constrained, opportunities in Africa and abroad have become potentially more lucrative with diversification considered a more prudent strategy.

Industry specific results show that pharmaceutical, chemicals, oil and gas, FMCG and retail companies in particular are planning expansion into select African markets.

”

Embracing Change

89% of respondents ranked identifying and managing change as their top business objective

”

The continued focus on increasing flexibility, agility and responsiveness and introducing new products and services to the market indicates that previous themes of customer centricity and creating a sustainable advantage are still top-of-mind agenda items for company executives. Sustaining existing areas of financial returns highlights the importance companies are placing on having a solid foundation in place from which to pursue new opportunities.

Implementing change in a business requires the balance between introducing and developing new opportunities whilst retaining the ability to sustain current incomes. Such a balance is more readily achieved in an environment of flexibility, agility and responsiveness.

Implementing change successfully requires finding the balance between introducing and developing new opportunities and remaining financially viable

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LOGISTICS

”

The top ranking objectives highlight South African companies’ need and desire to leverage, manage and control the elements of change more efficiently

The high level of challenges may well reflect the current economic climate and degree of frustration reflected elsewhere in the survey, resulting in a shorter term focus rather than visionary and expansive focus.

The cost of doing business is the top ranked constraint by respondents, up from second place in last year’s survey. With most input costs increasing, high levels of uncertainty, competition from low cost producing nations and a relatively flat economy, companies are focusing on cost effectiveness to remain competitive.

Business costs fall into two main categories, costs that can be controlled, and those which businesses have little or no ability to influence. Managing controllable costs is a key factor in creating and sustaining a competitive advantage and remains top of most companies’ focus areas.

It would appear though, that it is less about the willingness to change but rather the identified and articulated need to do so. The issue may well be identifying the need to change before being forced by circumstances to do so which relates to the role of seeking change for continuous improvement.

”

Respondents ranked the ability to anticipate change and adapt quickly as their second biggest constraint. This, coupled with the highest ranking business objective of identifying and managing change, clearly highlights the disruptive power of change.

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Respondents ranked the top supply chain challenge as the willingness to change/ breaking old habits/relationships which is invariably a leadership and communication issue.

The lack of relevant skills and talent dropped down from last year’s top ranked constraint, but remains a major constraint for respondents

LOGISTICS

It would appear that companies are embracing environmental sustainability but are potentially hindered by solutions lacking economic value.

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LOGISTICS

Supply chains have been transformed from support functions to being fundamental parts of business with the ability to differentiate companies from their competitors and play a key part in the achievement of business strategy.

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LOGISTICS

”

Improved partnerships, greater integration and alignment, as well as increased visibility from supplier to customer were seen as areas of greatest potential future returns

”

In identifying the performance of their companies’ critical elements to manage change, the respondents ranked their organisation’s ability to set a clear vision, strategy and objectives as the highest area of performance with 22% rating this as excellent and 42% ranking this as good. However, this high ranking of visionary ability and creation of clear strategies conflicts with previous responses in the survey.

The need for improvement is again present where respondents rated their performance of many of the other elements of change management as being good or average. Of particular note is that the empowerment of action and the ability to communicate reveals areas of concern as these are arguably some of the most important aspects of effective and successful management and implementation of change.

55% of respondents ranked their companies as average to poor at supporting change with training and learning sessions, which is a concern as the lack of relevant skills and talent was identified as one of the top constraints to achieving strategic business objectives

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LOGISTICS

�

Respondents from the Information Technology & Communication and Public Sectors ranked the highest for having dedicated functions to predict game changing trends but ranked the lowest for communicating a vision for change

�

Managing change is a strategic process requiring a strong sense of visionary leadership, a clear picture of the objective and reasons, and a strong process of communication and involvement.

The function of change management in many organisations is a team established to implement pre-determined changes and invariably is not involved in the monitoring of the need for change or the vision of what needs to change and why. Managing change is an executive role requiring the support of all those affected by it.

It is very positive to see that 71% of respondents said their partner organisations were applying a degree of focus on monitoring changes that affect the supply chain processes, but only 14% of respondents felt they did so at the same level as their companies.

In the retail industry there is a much higher degree of comfort from respondents that partners in the supply chain are monitoring change well. Respondents from the retail sector in general have displayed a more structured and disciplined approach to change and change management compared with other sectors.

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LOGISTICS

The supply chain is no longer seen as a support function, but as the backbone of business.

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LOGISTICS

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Measurements On Overland Conveyors This article discusses the importance of field measurement on conveyor belts for long term reliable operation of the conveyor system. Various field measurements acquired on different belt conveyor systems around the world are presented. Field measurements were acquired on these conveyors for a number of reasons including: commissioning; equipment and control system validation; system upgrades; and the investigation of equipment failures. Starting characteristics for various drive types are presented.

Equipment

Field measurements are perhaps the most valuable and interesting aspects of engineering. Regardless of what a manufacturer advertises about its equipment, or what “rumours and speculations” have been made about a system, or even how one’s own theoretical models predict a system should behave, actual field measurement provide an unbiased view of how the system is “really” behaving.

Figure 1. Vibration during starting – motors in load sharing control

The techniques and measurement equipment discussed in this paper have been previously discussed in detail by the authors.

However, on most conveyor systems the basic field measurements obtained are:

Shaft torque

Figure 2. Zoom-in of primary drive torque of vibration during starting

Strain gauges are directly applied to the low-speed shaft of a drive, brake, or backstop pulley. Wireless telemetry equipment is used to transmit the data from the rotating shaft to a data recorder. This is an extremely accurate method of measuring the forces being transmitted to the conveyor. It can also be used on almost any type of drive, brake, or backstop system. In some cases, strain gauges may also be applied to the high speed shaft of the drive or reducer (eg, to measure internal backstop torque or reducer losses).

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BELTCON

conditions as well as during starting and stopping.

Belt rotation

Useful on pipe conveyor installations to measure the belt rotation and tracking at various locations during loading and unloading.

PLC data

Weight scale data, motor amperage, drive and brake control signals and other pertinent information is normally acquired. This information is used in conjunction with the above measurements to obtain a more complete picture of the system operation.

Startup

Figure 3. Motor torque and belt speed – motors in speed control

Belt velocity

Velocity encoders are usually mounted at the head and tail ends of the conveyor to record the belt dynamics and transition shockwaves during starting and stopping.

Take-up position

Displacement wheels and encoders are installed to track the take-up displacement during transition conditions.

Horizontal curve displacements

Belt tracking and side travel are recorded to determine the belt displacements during load on/off

The following case studies discuss a few issues that the authors have encountered on site. In most cases these issues had to do with starting a fully or partially loaded conveyor.

Conveyor one The first conveyor installation is located inside the Arctic Circle with extreme temperature variations from -40°C to +25°C. This particular conveyor was one of several new systems. It is over 3 km in length with approximately 200 m of elevation gain and transports 8000 t/h of copper ore. The conveyor has four VFD drives totalling 9200 kW of installed motor power.

During commissioning there were significant vi-

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BELTCON

bration issues during starting, which prevented the system from starting with tonnages above 3000 t/h. AC-Tek was requested to visit the site and obtain accurate torque measurements on each of the motor shafts.

Vibration

Figure 1 shows the results of the initial measurements. The shaft torque on each of the drives is displayed along with the drive pulley velocity. During starting there were two main windows of significant vibration. The first occurred at a belt speed of approximately 0.1 to 0.7 m/s. The second occurred between a belt speed of 2.3 to 3.5 m/s. The second vibration was the largest and most substantial.

Figure 2 zooms in on the torque of the primary drive during the second vibration. The torque varies from 0 kN-m to 540 kN-m which is almost 90% of the motor nameplate rating for that drive shaft. This figure shows that motor 2 (M2) and motor 4 (M4) are oscillating against each other. These two motors are both located on the primary drive shaft.

Figure 4. Motor torque and belt speed – start with pre-tension step

The vibration was likely caused by a natural vibration mode of the motor and brake disk masses on the shaft.

The control of the motors was a masterslave relationship. The master VFD drive was controlled by a velocity feedback loop. The torque on the other three motors was set to load share with the master drive.

Control philosophy

After careful analysis of the resulting measurements, and after performing several dynamic simulations, the authors recommended changing the control philosophy such that each drive was controlled individually using only speed Figure 5. Motor torque and belt speed during empty belt start-up control. It was predicted that this type of control would eliminate the vibrations occurring available at that time). The belt started smoothly between motors on the same shaft. Figure 3 shows and without any problems. The system has now the motor torque and belt velocity after the control been in full operation for more than two years. had been changed. Both the initial and secondary vibrations were almost entirely eliminated after the Even though the conveyor was equipped with VFD drive control, direct strain gauge measurecontrol change. ments were still crucial in accurately identifying Pre-tension step and correcting the drive control issues. Combined The design of the conveyor required a pre-tension with dynamic analysis and theoretical predictions, step, which was not implemented in the control a stable starting control was implemented quickly system. The belt should be held at 5% of full speed and successfully. for a short time. This ensures the entire system Conveyor two is in motion before starting the main acceleration ramp. Pre-tensioning the belt provides smoother As this conveyor demonstrates, even though a acceleration, lower belt tensions, and minimises conveyor appears to be operating correctly and the transient tension waves. Figure 4 shows the final supplier asserts that everything is working, this start-up with the pre-tension step. The belt was may not be the case. There may still be serious fully loaded at 4750 t/h (which was the maximum problems which need to be resolved.

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This conveyor transports 6500 t/h of material at just under 6.0 m/s. The belt length is approximately 3.5 km and the system has a total installed power of 4350 kW. There are two drives on the primary drive pulley and one drive on the secondary. All three drives are "actively" controlled. The authors were consulted directly by the client at the end of the commission stage to ensure the system was indeed operating properly before being handed over to them. At this time the system was supposed to be functioning normally. However, after installing the test equipment the first empty and loaded starts proved otherwise.

Figure 5 shows the empty belt start-up.

The design specified the required starting Figure 6. Motor torque and belt speed during loaded belt start-up time of the conveyor to be 160 seconds with an initial 20 second pre-tensioning step at 4% speed. The actual measured starting time was only 62 seconds. The initial pre-tension step was very poorly controlled and although the second part of the velocity curve was relatively smooth, the acceleration rate was fast (28 seconds).

Acceleration curve

The fully loaded belt start-up is shown in Figure 6. Although the starting time had increased to almost 112 seconds, this was not acceptable. Furthermore, the velocity profile contained several regions of "dwell" periods with no acceleration followed by periods of rapid acceleration.

These abrupt acceleration regions are not acceptable as they result in significantly reduced belt safety factors and induce dynamic shockwaves into the system.

After discussions with the drive supplier, the authors were assured that the start- Figure 7. Motor torque and belt speed during loaded belt start-up up settings only needed to be slightly modified in order to provide a smooth acceleration curve. Various changes were made and several more fully loaded starts were measured. Although these changes slightly improved the velocity acceleration ramp, they resulted in even larger torque fluctuations during starting (Figure 7). The modifications also reduced the empty belt starting time to less than 20 seconds. This was clearly not acceptable.

Motor load shedding

Unfortunately this was not the only issue discovered during testing. As the conveyor was loaded, occasionally the motor load sharing would be lost between drives. Generally (but not always) Motor 1 would essentially "do its own thing" while the remaining drives continued to load share (Figure 8). At other times Figure 8. Loss of -motor load sharing on primary drive during steady state running BULK HANDLING TODAY

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field measurements. It's easy to see that the belt is starting, however, it is nearly impossible to "see" or "feel" problems such as load sharing or large torque oscillations unless the proper instrumentation has been installed. If such problems exist, they can reduce the reliability of the system and cause premature failures down the road. Without having completed field measurements, the client would not have known of the existing problems in the drive system.

Conveyor three This conveyor was over 12 km long, transporting 2400 t/h of coal.

The authors were again requested to be present for the full load testing and verify the installation was operating within the design parameters.

Figure 9. 110 second start-up of 12 km overland conveyor

Figure 10. Corrected 350 second start-up and excellent load sharing

during empty steady state running, the drive torque on one motor would drop to almost zero, remain there for 30–60 seconds, and then resume load sharing normally.

None of these anomalies were known by either the drive supplier or client at this point (and again this was at the end of the commissioning stage).

These measurements highlight the importance of field measurement at the time of commissioning. It can be very difficult to ascertain drive torque and belt speed during starting and stopping without

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After all equipment had been installed, several empty belt starts were performed to ensure the conveyor was starting properly. The system was controlled using VFD drives (two drive pulleys at the head, and one at the tail).

Although the empty belt starting curve was very smooth and the required pre-tensioning step had been implemented, the start-up time was only 110 seconds (Figure 9).

The design report had specified a start-up time of 350 seconds. This simple, yet critical, parameter had been checked and verified during empty belt testing, but somehow it had been changed. Fortunately this correction was easily made and the fully-loaded starting curve was nearly ideal (Figure 10).

Power failure

When a power failure occurred, it was discovered that the tail brake was not being immediately applied. When the authors inquired about this they were told by the PLC programmers that this brake was only a "parking brake" to be applied once the conveyor had come to rest. But this was not correct.

The reason for the brake is to prevent excessively

BELTCON

Figure 11. Typical loaded starting curve using fixed filled couplings

long drift times during a power failure stop when the decline section of the belt is loaded. Without reducing the drift time of the belt, the volume of the head chute is insufficient and would likely overfill. This issue, while easily corrected, shows the value in conducting an independent set of field measurements. It also demonstrates the need for periodic measurements to verify that the system is still operating as initially specified.

Increased capacity

The next case studies discuss how measurements were used to increase the capacity of the different conveyor systems.

Conveyor four This system consisted of multiple conveyors (with a total approximate length of 6000 m). The design capacity of the conveyors is 18000 t/h, however,

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the client could only achieve a maximum tonnage of 12000 t/h due to several problems. The authors were requested to perform measurements and a design audit of the conveyor to determine what actions were required to run full design tonnage on the conveyors.

Field measurements were an essential part of determining the path forward. They were to be used to determine the safe operating tonnage of the currently installed equipment, and also to establish what equipment upgrades would be necessary to meet the increased demand capacity.

Fluid couplings

The conveyors were driven by 850 kW motors.

Each conveyor had two to four motors depending on its length. Fixed filled fluid couplings were used on all conveyors. The oil fill level in these types of couplings is not actively controlled. The couplings contained a delay chamber so that the oil drained from the working chamber to the delay chamber when the motor was not rotating. In the final stopped position, a certain amount of oil remains in the working chamber and the rest is in the delay chamber. During start, the oil is pushed into the working chamber of the fluid coupling by centrifugal force. The rate of transfer from the delay chamber to the working chamber depends on various factors such as oil viscosity (which is a function of temperature) and the diameter of the nozzle holes (for oil transfer from delay chamber to working chamber).

Figure 11 shows motor torque and belt velocity on one of the conveyors at an average loading of 9500 t/h (approximately 50% loaded). This starting curve is characteristic of the starts of all conveyors on this particular system when loaded.

Torque

When the motors first turn on, the initial torque on each motor quickly rises to approximately 85%, 95%, 125%, and 150% of the motor nameplate

Figure 12. Water cooling of the fluid coupling during starting

rating. From the graph, the primary motor on the left side has a torque output of 85% nameplate torque at 12 seconds whereas the secondary motor on the right side has a torque output of 148% nameplate torque at 14 seconds. However, a few seconds after the peak initial torque, the output torque drops to 50% to 85% nameplate torque for the motors. It then lingers at this low torque values for some time. Finally, when the belt speed increases to 60% to 70% of full speed, the torque suddenly rises again.

Figure 11 shows high torque at the beginning and end of the start that can result in belt slip on the drive pulley if it is too high. Second, due to the low torque in the middle of the start, the fluid coupling may have insufficient torque and the belt may stall without starting. This low torque is a limiting factor to the maximum capacity of the conveyors and must be understood.

A fixed fill fluid coupling has a characteristic torque

Figure 13. Demand power vs. tonnage

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starting curve which is a physical attribute of the fluid coupling. The starting torque can be increased or lowered by changing the oil fill level in the fluid coupling. It must be understood that these curves do NOT change - it is a physical attribute of the fluid coupling. Each fluid coupling will have its own lambda curve; however, all the fluid couplings of the same model will be somewhat similar.

It must be noted that these couplings were from one specific manufacturer and thus are not representative of all couplings.

The authors have taken measurements on a wide range of coupling types, Figure 14. Demand power vs. tonnage manufactures, and sizes, and the resulting behaviours can be significantly shown in Figure 14. The conveyor has four 1305 different from one another. kW variable speed motors installed. The demand power at the current belt speed and 7200 t/h Field measurements Figure 12 shows the "normal" start-up procedure condition was approximately 75% nameplate. As used at the mine when the conveyor stops and the such, the predicted power consumption at 8800 belt is more than 50% loaded. The couplings are t/h was still acceptable and just under 90% of sprayed with a water hose in order to keep them the motor nameplate rating. cool while starting. This prevents the thermal fuses from blowing and having to refill the coupling oil levels. This is necessary due to the low torque that occurs when the couplings are starting, resulting in very slow acceleration. The field measurements were able to identify the allowable loading in the conveyor under which the belt could be safely started. Unfortunately the safe design capacity of the conveyors, due to the physical characteristics of fixed filled fluid couplings, is much lower than the design tonnage.

Over the course of several weeks, long term trending and steady state data was acquired from the PLCs and compared to the field measurements. Figure 13 shows the results from one conveyor over a range of tonnages. Each data point represents a fixed steady state period where a constant loading of the conveyor was achieved over a specific time period. This data, combined with the loaded starting information, was essential in determining the required modifications to increase the conveyor capacities to 18000 t/h throughput.

Conveyor five

The next conveyor is approximately 3.1 km in length, transporting copper ore at 7200 t/h. The client wanted to increase the capacity to 8800 t/h.

Field measures were made to determine the current operating condition of the conveyor and what, if any, changes would be required to accomplish this update. The measured power consumption is

Belt dynamics

As Figure 14 shows, the starting control and motor load sharing was excellent. The dynamic behaviour of the belt was also verified under a fully loaded power failure condition. Using this information, the belt dynamics were again simulated at the higher capacity. The results showed that no dynamic problems would be expected at the higher tonnage.

However, the belt safety factor at the increased tonnage was below the acceptable level for the client. Furthermore, the cross-sectional material loading on the belt exceeded the 110% CEMA loading. It was therefore recommended that the drive pulleys be replaced with the next largest diameter. This resulted in an increased belt speed which in turn decreased the material cross-sectional loading to acceptable levels. The belt safety factors also increased to satisfactory levels, and there was still sufficient power to meet the design tonnage.

This paper has been condensed due to space constraints.

It was first presented at Beltcon 17 in 2013. The authors are David J. Kruse and Ryan Lemmon from Advanced Conveyor Technologies (AC-Tek) and copyright is vested with the IMHC. www.beltcon.org.za

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MARKET FORUM

Doubling Productivity

A major project is underway at the Boliden-owned Garpenberg Mine in central Sweden to increase production from 1.4 Mt to 2.5 Mt in 2015. Key to achieving this goal is a revision of the company’s haulage strategy.

Until now, the mine, which produces lead, zinc, silver and gold concentrates, has relied on general-purpose road trucks to haul the ore to the surface. However, with effect from January 2015 these

vehicles are being replaced by a fleet of Minetruck MT42 trucks developed and manufactured by Atlas Copco.

The new trucks load 42 tonnes while the trucks that have been used until now only take 28 tonnes. That’s an improvement of about 40 percent which will make a big difference to productivity.

Tyre consumption is also an important cost factor. As the tyres on the Minetruck MT42 are adapted for the tough mining

environment, they last much longer than standard road tyres.

The cabin on the Minetruck MT42 is Fops/ Rops approved which means they are built to withstand rockfalls and protect the drivers. In addition, the cabins are ergonomically designed and comfortable.

Atlas Copco, Ditumiso Mahlaba Tel: (011) 821-9572 ditumiso.mahlaba@za.atlascopco.com www.atlascopco.co.za

Bulk Vehicle Blowers Generating positive pressure for the pneumatic unloading of dry bulk material and generating negative pressure for the suction of waste materials can be achieved using a range of specialised, oil-free bulk vehicle blowers, low pressure screw compressors and vacuum blowers produced by German-based Aerzener Maschinenfabrik (Aerzen).

Marketing co-ordinator, Andreas Stubel, says that the Aerzen bulk vehicle blower range has been specifically designed to meet the unloading requirements of specialised bulk transport vehicles, which haul dry fine powders such as flour and cement, or food products like sugar and animal feed.

The bulk vehicle blowers have a two-lobe design in either a horizontal or vertical flow configuration. The

machine range produces intake volume flows up to 1600 m3/h, with a maximum offloading pressure of 1 000mBar at sea level. The drive is via direct coupling or via a narrow v-belt.

“During unloading, the blower pumps air

into the storage tank system of the truck, fluidising the product and forcing it out through valves into the discharge piping at the bottom of the tank. Our range is ideally suited for this application due to its compact design, reliability, high quality and a strong backup service from Airgas Compressors,” Andreas explains.

A stand-alone solution for bulk vehicle unloading is also available in the form of an oil-free screw compressor unit. The Aerzen Delta Screw VML18R has proven to be an ideal machine for the bulk unloading process, especially in the local flour milling industry where its popularity is growing rapidly.

Airgas, Andreas Stubel Tel: (011) 474-2193, www.airgas.co.za Email: astubel@airgas.co.za

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MARKET FORUM

Cashless Fuel Payments in Africa

Engen offers commercial customers in Africa, a reliable and safe cashless payment system in the form of their 1-Card, which is able to operate in areas where connectivity is not always optimal.

The card eliminates the need for drivers in the fleet to carry money allowing them to have better control over their fuel expenditure through our reporting system,” says Drikus Kotze, general manager of Engen’s International Business Division.

“The 1-Card ensures a safe and convenient way for fleet managers to control their fuel spend in the countries in which we operate.”

Administered by Engen, the 1-Card costs a fraction of bank-issued petrol cards and has no transactional fees or monthly administration charges. The system can be tailored to the individual needs of each fleet such as whether a pre-or post-paid account is preferred.

Fleet managers have improved control over fleet expenses as they can now determine when and where each 1-Card can be used as well as how much can be spent on the card. In addition, fleet operating businesses are able to receive

a monthly itemised report with an overview of fuel expenditure.

The system uses an advanced technology platform which is able to accommodate offline functioning. The chip technology on the 1-Card ensures that all of the information needed at point of sale is stored on the card, necessary in areas where connectivity is unstable at times.

This information is relayed to Engen’s servers at least once a day.

Additionally, each card is issued with a unique pin number and a vehicle identification tag which is affixed to the fleet vehicles’ windscreen and scanned during the transaction. Each tag is specific to the card and cannot be used without scanning the tag.

The 1-Card offering is available at sites in the following countries within which Engen operates: Burundi, Democratic Republic of Congo, Gabon, Ghana, Mauritius, Mozambique, Reunion, Rwanda, Tanzania, Zambia, Zimbabwe, and can be applied for at Engen offices in these countries.

Engen, Gavin Smith, Tel: (021) 403-4312 Email: Gavin.Smith@engenoil.com

Log onto www.promech.co.za to read this issue on-line BULK HANDLING TODAY

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MARKET FORUM

Hidden in the Cargo As an increasing amount of merchandise is transported across the country, the risk of truck hijackings increases too. Fleet managers can combat this scourge with an innovative cargo tracking device available through QCIC. QCIC director Brian McKenzie notes that QIC-LOC can be discreetely placed in the cargo without the driver or other personnel knowing its location. “This ensures that the device is secure and cannot be easily found if the cargo is stolen. Once the cargo has reached its destination, a preselected employee will know where to find the device in order to remove it and turn it off.”

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The QIC-LOC asset management device features a car alarm, an electronic log book function, flexible asset management, and flexible driver and staff management.

It also boasts a 24/7 system health check, a panic button for emergency and alarm notification, and an intelligent internal power supply and management system. An incorporated GPS provides a location accurate to within 3m, and the ‘mark-a-position’ button allows the

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user to record the position at any time.

Brian highlights that it is important for tracking technology to be made smaller and more difficult to find, as it is no longer sufficient to simply track the vehicle or container. “Thanks to jamming technology, criminals have the ability to block the transmission of the tracker, which enables them to drive the vehicle to a location where the cargo can be off-loaded onto another vehicle or at a warehouse. After the truck is abandoned, the cargo cannot be tracked,” he adds.

QIC-LOC also consumes minimal power, as it is only active when in motion, thanks to a movement sensor. The device will automatically shut down if it has not moved for a predetermined period. On average, it can travel approximately 2500km before needing to be recharged.

In a situation where the device is not in motion, the battery can last up to six months without charge.

QCIC, Brian McKenzie, Tel: (012) 682 1621 Email: brian.mckenzie@qcic.co.za www.qcic.co.za

Haulage Trucks In a major contract award, Eqstra Industrial Equipment (“EIE”) has delivered 13 Terex Trucks TR100 rigid dump trucks to MCC, Eqstra’s Contract Mining & Plant Rental Division, to be deployed for the project awarded at Karowe Diamond Mine, located in the diamond-rich Letlhakane region of Botswana.

EIE will also provide MCC with comprehensive aftermarket support for the TR100 trucks, covering parts, service, general maintenance and repairs.

As the largest rigid dump truck in the Terex line-up, the 100 ton payload truck features a heaped capacity of 57m3 and is powered by a 783kW Cummins KTA38-C engine. This exceptionally fuel efficient, heavyduty engine, has been calibrated

specifically for hauler applications for a powerful performance, proven long lifecycles and reduced maintenance and operational costs.

The engine drives through an efficient, six-speed, automatic, electronicallycontrolled transmission, with automatic lock-up in all speed ranges, improving fuel efficiency and aiding productivity on site.

The TR100 truck’s rugged construction and durable components are designed for excellent service life, while the high capacity body with exhaust heating ensures excellent retention and cleaner dumping for increased productivity.

Eqstra Industrial Equipment (“EIE”), Karen van Diggelen, Tel: (011) 571-0294 Email: karenv@eiegroup.co.za

MARKET FORUM

Heavy Lift Completed

used to assemble the new mill. These components weighed about 60t to 70t each. “We then brought in a LR 1600/2 600t crawler crane from Europe to take off the gears and remove the old mill and install the new one, as we were concerned our LR 1750 Liebherr crawler crane was not going to finish on time at a project at Nacala in Mozambique,” Grant explains.

Johnson Crane Hire had a tight window from 29 September to 22 October 2014 to complete the heavy lift project, which was when the Selous Metallurgical Complex had a shutdown period. The 600t crawler crane completed the lift on 13 October, well within the timeframe.

LR 1600/2 600 t crawler crane

Johnson Crane Hire’s Heavy Lift Division has completed a major heavy lift project at Zimplats’ Selous Metallurgical Complex in Zimbabwe for client FLSmidth. The mechanical contractor was Competitive Construction Services (CCS) of Vanderbijlpark, Gauteng. “We were contracted to remove an old mill weighing 225t, with a radius of 31m, and to replace it with a new one weighing 170t,” Grant

Log Stackers The Taylor range of materials handling equipment, distributed exclusively in South Africa by BLT SA, encompasses the TXLS series log stackers, designed to efficiently handle a full log load, from truck or rail, in a single pass.

“These robust log stackers, which are used for loading, stacking, transporting and unloading heavy loads of logs, offer improved productivity and safety, as well as fuel efficiency, reduced exhausted

Parker, project manager at Johnson Crane Hire, says. The successful completion of the project marked the culmination of two years of detailed planning and engineering.

Johnson Crane Hire placed a 250t crawler crane on site at the Selous Metallurgical Complex since the beginning of September 2014, which was

Parker adds that the use of the 600t crawler crane in particular not only reduced the downtime at Selous, but also contributed to greater safety on site.

“FLSmidth is an established client of ours and we have done work for them in the past, as we have for Zimplats, with which we have a very good relationship.

In fact, our 250t crawler crane went straight onto another job at the Ngezi concentrator for Zimplats.”

Johnson Crane Hire, Peter Yaman Tel: (011) 455-9242 www.jch.co.za

emissions and low maintenance requirements,” says Charity Gumede, marketing director, BLT SA.

ity cooling system for operation in all environments and engine/transmission protection systems.

“There are three models in the TXLS range – TXLS-800, TXLS-900 and TXLS1000 – which are built on an all welded, high strength steel chassis and frame, with heavy duty drive and steer axles.”

Lower fan and engine speeds reduce noise levels during operation and a builtin shut down system for the engine and transmission (high coolant temperature and low oil pressure) is standard. A high performance non-metallic pusher fan blows dust and debris away from the operator.

These log stackers are fitted with Tier III turbocharged diesel engines, with low emissions and efficient fuel economy.

Standard engine features include an fuel/water separator, a high capac-

This series has been designed for easy maintenance procedures to reduce downtime. An electronic diagnostic and maintenance monitor on the engine has a fault code history for fast problem location. The mast pivot housing is a two piece bolt-on structure for easy and safe service removal.

BLT SA, Charity Gumede Tel: (031) 274-8270 Email: info@blt.co.za www.blt.co.za

TXLS log stackers are designed to efficiently handle a full log load, from truck or rail, in a single pass

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MARKET FORUM

AFRICA’S PREMIER CONSTRUCTION AND MINING TRADE FAIR

PBS Vehicles

R !

E FO ANC RATIONS R T N T E IS FREEINE REG /en/ ONL com rica. ration f a c b t . wwwors/regis visit

Timber24, a local timber transporter, has introduced its new fourth generation PBS timber vehicles – marking a first for the local industry.

These unique Australian simulation vehicles enable a 10 - 15% cost saving in the delivery cost to customers. By equipping PBS vehicles to carry higher payloads per trip, for example, fewer

trips are needed, thereby reducing road risk and exposure by up to 25%.

Says Blake Ferguson, MD of Timber24, "The game-changing innovations are improvements on the old PBS design, for example, adjusting the underslung hitch position; hanging the A-frame design and shortening the trailer length.

These modifications all focus on making

RentalSolutions Bobcat Equipment Rental and Goscor Access Rental joined forces to provide an end-to-end lifting equipment solution to meet essential materials handling duties during the construction of a wind farm in the Western Cape.

Brent Viljoen, branch manager of Goscor Access Rental in the Western Cape, says, “By joining forces with Bobcat, we could provide the customer with a complete rental solution consisting of telescopic handlers and work-at-height machines, qualified operators and back-up service.

International Trade Fair for Construction Machinery, Building Material Machines, Mining Machines and Construction Vehicles.

WWW.BCAFRICA.COM

MMI/BCA/Quirk/CEN

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“I approached Bobcat Equipment Rental, Western Cape, and the company immediately came with its A-game. The combined strengths of the two divisions enabled us to offer the customer an excellent group deal culminating in our securing the two-part rental contract in 2014.”

“We conducted site visits to familiarise ourselves with the boundaries to which our machines would be used so that we could offer the best solution, from equipment rental to highly trained operators and back-up service,” Brent concludes.

Non-intrusive Measurement Vishay’s Model 178 extensometer is a load sensor designed for force measurement on any load-bearing structure. This extensometer provides the total solution for weighing, level control, stress and fatigue monitoring. The design also allows multiple sensors to be permanently mounted for more complex stress profiling and analysis.

the combination as short as possible, without sacrificing payload or safety and all of these changes equate to a significant annual savingwhich is shared by the customer and the haulier,� Blake concludes Barloworld Transport, Tel: (033) 395-7400 www.barloworld-transport.com

The Model 178 extensometer provides the solution for non-intrusive level measurements for materials that are subject to uneven buildup, bridging, or sidewall collection. Also, liquids or wetted materials that are not suited for direct contact level measurement are an ideal application for the Model 178 extensometer. Its design makes it an excellent solution for retrofitting existing structures without compromising the integrity of the vessel or structure.

In terms of the rental equipment specifications, the work-to-height machines had to lift workers to a maximum height of 26m while the telescopic handlers had to have minimum lifting capabilities of 4 tons. All the equipment had to be diesel driven and had to ably cope with traveling over uneven, rough terrain.

Goscor Access Rental, Brent Viljoen, Tel: (010) 593-6916, Email: BViljoen@goscor.co.za Bobcat Equipment, www.bobcat.co.za Email: bobcat@goscor.co.za

The 178 has application in tank weighing or level systems, agricultural equipment, rolling mill sensing, moment sensing, structural loading measurements and bridge structures.

Instrotech Tel: (010) 595-1831 Email: sales@instrotech.co.za www.instrotech.co.za

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MARKET FORUM

Truck Tyre Recycling A multi-million rand investment in a rubber crumb manufacturing plant in Hammarsdale will take rubber tyre recycling to a whole new level in KwaZulu-Natal.

The new facility will be the new home of the Mathe Group, one of only two KwaZulu-Natal companies registered with tyre recycling regulatory body, Redisa.

The Mathe Group currently recycles waste truck tyres in an 850 sq/m facility in New Germany. Its new factory, which was commissioned in April this year, comprises a 2 500 sq/m factory and a 1 000 sq/m warehouse. It will be fitted out with R20 million worth of state-of-the-art equipment.

At capacity, the Mathe Group’s New Germany facility processes six tons of radial truck tyres per day.

Each truck tyre weighs approximately 68

kg. Between 15 and 20 percent of the tyre is steel which is separated from the rubber and provides an additional revenue stream for the company. The steel is sold onto other recyclers and a large portion is exported to India.

The Mathe Group processed approximately 28 000 truck tyres during 2014. Over the next five years, this number is expected to dramatically increase to approximately 150 000 tyres, which will produce approximately 8,670 tons of rubber crumb.

The new factory and warehouse in Hammarsdale will accommodate multiple deliveries and stockpile tyres for recycling.

PFE International, Mehran Zarrebini, Tel: (031) 913-3800

Rubber crumb granulate produced after sieving

Benefits include improved crown strength and flex resistance, particularly at the sealing ring area; superior protection against excessive oil consumption, operating temperatures and combustion blow-by; and an improved design compared with onepiece piston designs with two-piece oil dam inserts.

IPD Parts

Metric Automotive Engineering has announced the availability of IPD parts for Caterpillar C15 engines for mining and industrial applications. These include cylinder kits and components such as a new IPDSteel friction welded piston design (patent pending), which features an integral cooling oil reservoir formed in the crown.

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These kits are available with a standard OE style liner, and also with IPD’s innovative IPDStyle Crevice Seal Liner for superior performance. The crevice seal is a wide rectangular shape seal placed into a special tapered liner groove, which provides a wider contact surface deeper into the engine block for improved sealing, and a wedge effect when the liner is installed for securing the liner firmly, thus minimising liner movement.

Metric Automotive Engineering Andrew Yorke, Tel: (011) 873-2350 Email: andrew@metricauto.co.za www.metricauto.co.za

May 2015

Index to Advertisers Afzelia 14 AMD-Rotolok 28 Aury Africa

45

Bauma Conexpo

44

Becker Mining

41

BMG 26 CIS

Outside Back Cover

Industrial Showcase

33

ILS 24 Kaletsa 15 KZN Industrial Expo

38

Martin Engineering

42

Megaroller

Inside Front Cover

MEIndaba 36 Melco

Outside Front Cover, 11

Nkosi’s Haven PowerGen Africa QS Association Renold Crofts

34 30 20, 40 15

SAID 38 Sandvik

Inside Back Cover

SEW 12 Tega Industries

16

ThyssenKrupp 10

DRIVING TECHNOLOGY DELIVERING PRODUCTIVITY Sandvik Mining is your single-source design, project construction and management provider for multi-disciplinary mining systems projects. Whatever your bulk materials handling need, we’ve got you covered. We specialize in underground, in-plant and long complex overland conveying systems, crushing and screening plants, total stockyard systems including stackers and reclaimers, spreader systems, IPCC systems, shiploaders and export terminals.

For enquiries, please contact +27 (0) 11 657 4600 MINING.SANDVIK.COM

BULK HANDLING TODAY

May 2015

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